Asphalt Emulsion Dust Control for Corrosion-Free Coal Hoppers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Industrial operations, particularly those involving coal transportation, face significant challenges with fugitive dust that poses environmental and health hazards, leading to material loss and infrastructure damage, and existing dust control methods like halide brines can cause corrosion and surface damage.
Innovation Solution
The development of asphalt-based emulsion formulations that can be used in wet spray systems to control dust by binding particles and providing anti-corrosion properties, reducing airborne dust particles by up to 98% and maintaining effectiveness even after drying.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If halide brines are used for dust control, then dust suppression is effective, but corrosion and surface damage occur
Solution Approach 1:
The patent changes the chemical composition parameters of the dust control solution by using asphalt emulsion instead of halide brines. This parameter change maintains dust suppression effectiveness while eliminating the corrosive properties of chloride salts, thereby resolving the contradiction between dust control effectiveness and corrosion prevention
Solution Approach 2:
The patent employs a composite formulation consisting of asphalt emulsion combined with specific additives (corrosion inhibitors, surfactants, and thickening agents). This composite material approach creates a dust control solution that leverages the protective and adhesive properties of asphalt while incorporating functional additives to enhance corrosion resistance and dust suppression performance
2Object-generated harmful factors
If water sprays are used to control dust, then dust capture is achieved, but material loss and infrastructure damage occur
Solution Approach 1:
The patent changes the physical and chemical parameters of the spray solution by using asphalt emulsion with controlled viscosity and adhesion properties. This allows the solution to bind to particles and surfaces effectively, capturing dust while forming protective coatings that prevent material loss and infrastructure damage from corrosive water-based solutions
Solution Approach 2:
The asphalt emulsion acts as an intermediary substance that mediates between the dust particles and the environment. It binds to dust particles and surfaces, providing a protective barrier that prevents direct contact between corrosive elements and infrastructure, thereby reducing material loss and damage while maintaining effective dust capture
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The asphalt-based emulsion effectively reduces airborne dust particles, prevents corrosion, and maintains dust control and adhesion properties, addressing the hazards and infrastructure issues associated with fugitive dust in industrial operations.
Implementation Method 1
asphalt-based emulsion formulations that can be used in wet spray systems to control dust by binding particles
Implementation Method 2
binding particles and providing anti-corrosion properties, reducing airborne dust particles by up to 98%
Implementation Method 3
asphalt-based emulsion formulations that can be used in wet spray systems to control dust by binding particles and providing anti-corrosion properties
Data Source
AI summary
This disclosure describes formulations and methods for dust control, for example, coal topping, a term which refers to the application of liquid products to the top of coal loads, such as those in open topped coal hopper railcars as commonly used today to transport coal. Disclosed herein are asphalt-based emulsion formulations that accomplish dust control during industrial operations in which dust handling is required.